Automatic identification of components for welding and cutting torches

Abstract

Automatically identifying interchangeable torch components, such as consumables, for welding and cutting torches includes adding one or more passive markings to a surface of an interchangeable torch component. Then, automatic identification can be effectuated by a torch assembly including a torch body and one or more imaging devices or a system including the torch assembly and a power supply. The torch body has an operative end configured to removably receive one or more interchangeable torch components including one or more passive markings. The one or more imaging devices are positioned to optically acquire an image of or image data representative of the one or more passive markings included on the one or more interchangeable torch components so that the one or more interchangeable torch components can be automatically identified based on the one or more passive markings. Consequently, various components can be reliably and consistently identified.

We claim: 
     
       1. A torch assembly for welding or cutting operations, comprising:
 a torch body with an operative end configured to removably receive one or more interchangeable torch components including one or more markings, the torch body defining an internal cavity; and 
 one or more imaging devices disposed within the internal cavity and positioned to optically acquire an image of or image data representative of the one or more markings included on the one or more interchangeable torch components so that the one or more interchangeable torch components can be automatically identified based on the one or more markings. 
 
     
     
       2. The torch assembly of  claim 1 , further comprising:
 one or more light sources configured to illuminate the one or more markings included on the one or more interchangeable torch components. 
 
     
     
       3. The torch assembly of  claim 2 , further comprising:
 a memory; and 
 a processor that executes instructions stored in the memory so that the processor operates the one or more imaging devices and the one or more light sources. 
 
     
     
       4. The torch assembly of  claim 3 , wherein the processor further:
 transmits the image or the image data to a power supply so that the one or more interchangeable torch components can be automatically identified based on the one or more markings. 
 
     
     
       5. The torch assembly of  claim 3 , wherein the processor operates the one or more imaging devices and the one or more light sources at predetermined intervals that are at least one of time-based intervals and action-based intervals. 
     
     
       6. The torch assembly of  claim 1 , wherein the one or more imaging devices comprise at least a single camera and the one or more markings are disposed on portions of the one or more interchangeable components that are optically viewable by the single camera. 
     
     
       7. The torch assembly of  claim 1 , further comprising:
 a memory; and 
 a processor that executes instructions stored in the memory so that the processor:
 operates the one or more imaging devices; and 
 analyzes the image or the image data with optical recognition techniques to automatically identify the one or more interchangeable torch components based on the one or more markings. 
 
 
     
     
       8. The torch assembly of  claim 7 , wherein the processor further:
 transmits instructions to a power supply to adjust operational parameters for the torch based on an identity of the one or more interchangeable torch components determined by the automatic identifying. 
 
     
     
       9. The torch assembly of  claim 1 , wherein the one or more interchangeable torch components are consumable components and the one or more markings are included on optically viewable portions of the consumable components. 
     
     
       10. A system, comprising:
 a torch assembly including:
 a torch body with an operative end that receives an interchangeable torch component with one or more passive, mechanical markings; 
 an imaging device that is disposed within or on the torch body; and 
 a torch component that is removably coupleable to the torch body, the torch component including one or more passive, mechanical markings on a surface that is optically viewable by the imaging device when the torch component is removably coupled to the torch body so that the imaging device can optically acquire an image of or image data representative of the one or more passive, mechanical markings; and 
 
 a power supply that automatically adjusts operational parameters based on the one or more passive, mechanical markings. 
 
     
     
       11. The system of  claim 10 , wherein the torch assembly transmits the image or the image data to the power supply and the power supply identifies the one or more passive, mechanical markings with optical recognition techniques so that the power supply can automatically adjust the operational parameters. 
     
     
       12. The system of  claim 11 , wherein the power supply:
 determines an identity of the torch component based on the one or more passive, mechanical markings; and 
 adjusts the operational parameters of power delivered to the torch based on the identity. 
 
     
     
       13. The system of  claim 10 , wherein the torch assembly further comprises:
 a light source configured to illuminate the one or more passive, mechanical markings included on the torch component. 
 
     
     
       14. The system of  claim 13 , wherein the torch assembly further comprises:
 a memory; and 
 a processor that executes instructions stored in the memory so that the processor operates the imaging device and the light source at predetermined intervals. 
 
     
     
       15. The system of  claim 10 , wherein the imaging device comprises at least a single camera. 
     
     
       16. The system of  claim 10 , wherein the one or more passive, mechanical markings are three-dimensional passive, mechanical markings and the imaging device is configured to detect at least one of a depth of the three-dimensional passive, mechanical markings and a profile of the three-dimensional passive, mechanical markings. 
     
     
       17. A method of identifying interchangeable torch components, comprising:
 optically acquiring an image of or image data representative of one or more passive markings included on one or more interchangeable torch components installed on or in a torch body by operating one or more imaging devices disposed in or on the torch body; and 
 identifying the one or more interchangeable torch components based on the one or more passive markings. 
 
     
     
       18. The method of  claim 17 , wherein the image is a raw image or a processed image, and the method further comprises:
 transmitting the image or the image data to a power supply so that the one or more interchangeable torch components can be automatically identified based on the one or more passive markings. 
 
     
     
       19. The method of  claim 17 , further comprising:
 analyzing the image or image data with optical recognition techniques to automatically identify the one or more interchangeable torch components based on the one or more passive markings. 
 
     
     
       20. The method of  claim 19 , wherein the analyzing is performed by a processor included in the torch and the method further comprises:
 transmitting instructions to a power supply to adjust operational parameters based on an identity of the one or more interchangeable torch components determined by the automatic identifying. 
 
     
     
       21. A consumable component that is removably coupleable to a torch configured to automatically adjust operational parameters based on an identity of consumable components installed therein, the consumable component comprising:
 a surface that is optically viewable at an operative end of the torch; and 
 one or more passive, mechanical markings disposed on the surface, the one or more passive, mechanical markings providing information relating to at least one of:
 an identity of the consumable component; 
 an operational parameter associated with the consumable component; and 
 a presence of the consumable component in a requisite location within the torch. 
 
 
     
     
       22. The consumable component of  claim 21 , wherein the surface is a rear end wall of the consumable component. 
     
     
       23. The consumable component of  claim 21 , wherein the one or more passive, mechanical markings include a trademark identifying a manufacturer of the consumable component. 
     
     
       24. The consumable component of  claim 21 , wherein the one or more passive, mechanical markings comprise machine-readable markings. 
     
     
       25. The consumable component of  claim 21 , wherein the surface is viewable by an imaging device included in a torch assembly including the torch and the imaging device is configured to acquire an image of or image data representative of the one or more passive, mechanical markings included on the surface so that the operational parameter associated with the component can be determined.